ABB SACE Emax 2 E2.2 Installation instructions
—
INSTRUCTION HANDBOOK
1SDH002304A1001 - ECN000285442
EMAX 2 E2.2
Disassembly instructions
3
Disassembly instruction emaX 2 e2.2
1. SCOPE
Scope of this document is to illustrate the step-by-step disassembly process of ABB SACE Emax 2 E2.2
air case circuit breaker equipped with an electronic trip unit (type Ekip TOUCH).
Document is focused on Emax 2 E2.2 3p IEC version, anyway it allows to cover other versions of Emax
2 E2.2 circuit breaker equipped with an electronic trip unit with just few slight differences to be taken
into account.
Gloves Glasses Safety shoes Protective clothes
4. TOOLS
Disassembly operations require the use of tools (e.g. screwdriver, torx key, pliers, …); tools to be used
are specified inside each phase of the disassembly process (see Chapter 6).
3. PERSONAL PROTECTIVE EQUIMENT (PPE)
When performing disassembly, following safety Personal Protective Equipment (PPE) must be worn:
2. SAFETY NOTES
Before proceeding with any disassembly operation, it’s mandatory to put the circuit breaker in open
position and make sure that the springs of the operating mechanism are discharged.
For handling and lifting circuit breakers refer to section “Unpacking and handling” of Emax 2 “Installa-
tion, operation and maintenance instructions for the installer and the user” document. Improper lifting
can result in death, serious injury to persons and damage to the equipment; never lift a circuit breaker
above other people. The trained personnel in charge of handling and lifting must use appropriate safe-
ty equipment.
Disassembly operations of circuit breakers must be performed by qualified and skilled personnel in
the electrical field (IEV 195-04-01: person with relevant education and experience to enable him or her
to perceive risks and to avoid hazards which electricity can create) and having a detailed knowledge of
circuit breakers.
Disassembly activites must be performed in an ergonomic workspace able to ensure protection of per-
sons demanded to perform disassembly activities.
Applicable national legislation and international standards in force at the time of disassembly of circuit
breakers must be taken into account in addition to prescriptions illustrated in this document.
ABB declines any responsibility for injury to people or damage to property resulting from a failure to
comply with the instructions set out in this document and with any applicable safety standard.
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INSTRUCTION HANDBOOK
Description Position inside circuit breaker Quantity
Base In sliding contacts block
Cover In sliding contacts block
Auxiliary position contacts cap In sliding contacts block
Right side wall In sliding contacts block
Flat cables assembly In sliding contacts block
Connector cables assembly In sliding contacts block
Sliding contacts base In sliding contacts block
Ekip measuring blind module printed circuit board Mounted on the trip unit
Plug Mounted on the trip unit
Rating plug printed circuit board Mounted on the trip unit
Rating plug case Mounted on the trip unit
Mounted on the trip unit
Battery cover Mounted in the trip unit
Battery Mounted in the trip unit
Display printed circuit board Mounted in the trip unit
Display Mounted on the trip unit
Back plane Mounted on the trip unit
Trip unit case Mounted on the trip unit
Trip unit back cover Mounted on the trip unit
Trip unit printed circuit board Mounted in the trip unit
Mounted on the terminal box
Mounted in the terminal box
Connectors Mounted on the terminal box
Mounted on the terminal box
Mounted on the terminal box
Terminal box case Mounted on the terminal box
Left MID On the left part of the circuit breaker
CD block cover Mounted in the CD
Front of the CD Mounted on the CD
Position indicator Mounted in the CD
Feeler Mounted in the CD
CD block lever Mounted on the CD
Releases door Mounted on the MID
MID pawl Mounted on the MID
Spacers Mounted in the MID
MID reset lever Mounted in the MID
Mechanical reset anchor Mounted in the MID
Trip coil support base Mounted in the MID
Trip coil cover Mounted in the MID
Trip coil Mounted in the MID
Flat cover Mounted on the MID
5. SEPARATE TREATMENT
Table below lists parts requiring a separate treatment adding information about part location inside
circuit breakers and related quantity.
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Disassembly instruction emaX 2 e2.2
If disassembled parts require a separate treatment a specific indication is provided inside each phase
with reason why for the separate treatment (see Chapter 6).
6. DISASSEMBLY PROCESS
Circuit breakers disassembly process is constituted by a sequence of operations to be performed on
products after their dismounting from original installation. For each phase following information are
provided:
applicable)
Description Position inside circuit breaker Quantity
Auxiliary flat assembly Mounted on the MID
RTC micro lever Mounted in the MID
MID main structure Mounted in the MID
Springs charging lever Mounted on the operating mechanism
Operating mechanism Mounted on the center of the circuit breaker
Auxiliary contacts cam Mounted on operating shaft assembly
Cam Mounted on operating shaft assembly
Lever Mounted on operating shaft assembly
Measuring module connector Mounted behind the trip unit and connected with poles
Protections Mounted in correspondence of rear terminals
Spacers Mounted in correspondence of rear terminals (for UL only)
Arc quenchings Mounted in arcing chambers
Spacers Mounted in arcing chambers
Sensors plugs Mounted in poles
Sensors Mounted in poles
Cables Mounted in poles
Insulating protections Mounted in poles
Insulation protections Mounted in poles
Contacts spacers Mounted in poles
current rating up to 1600A
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INSTRUCTION HANDBOOK
Tools
Torx key
Flat screwdriver
6.1 PHASE 1 – CIRCUIT BREAKER FRONT COVER AND OPERATING
MECHANISM COVER
1
By means of the flat screwdriver turn of 90°
the 2 screws fixing the trip unit transparent
protection to the circuit breaker.
4
By means of the cross screwdriver unscrew the
4 screws fixing the front cover to the circuit
breaker main structure.
6
By means of the torx key unscrew the 2 screws
fixing the 2 plugs to the front cover.
3
Manually remove the racking in and out lever
located in the bottom part of the circuit
breaker.
5
Manually remove the front cover.
2
Manually remove the trip unit transparent
cover.
Actions to be performed
Cross screwdriver
No. 8
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Disassembly instruction emaX 2 e2.2
7
Manually remove the 2 plugs.
11
By means of the flat screwdriver push the pin
as indicated by the arrow and after let the
the spring and the T.U. Reset signalling plug
automatically separate from the T.U. Reset
metal support.
9
Manually remove the T.U Reset assembly.
8
By means of thr torx key unscrew the 2 screws
fixing the T.U. Reset assembly to the front
cover.
12
By means of the torx key remove the 2 screws
fixing the plug to the circuit breaker front
cover.
10
By means of the flat screwdriver remove the 2
benzings mounted on the T.U. Reset assembly.
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INSTRUCTION HANDBOOK
13
Manually remove the plug.
15
By means of the cross screwdriver unscrew
the screw located on the side of operating
mechanism cover.
14
Manually push down the springs charging lever
and by means of the cross screwdriver unscrew
the 2 screws located behind the springs
charging lever fixing the operating mechanism
cover to the circuit breaker main structure
and always by means of the cross screwdriver
unscrew the screw located in the bottom right
part of the operating mechanism cover fixing
it to the circuit breaker main structure.
16
Manually complete the removal of the
operating mechanism cover.
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Disassembly instruction emaX 2 e2.2
Disassembled parts
Metal)
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INSTRUCTION HANDBOOK
6.2 PHASE 2 – SLIDING CONTACTS BLOCK
Actions to be performed
Tools
Torx key
No. 8
No. 30
Pliers
Flat screwdriver (x2)
Cutter
17
By means of the torx key (size 30) unscrew the
both sides of the sliding contacts block to the
circuit breaker main structure.
20
Manually remove the base and the cover.
19
Move the sliding contacts block as shown in
the picture and by means of the torx key (size
8) unscrew the 6 screws fixing the base and
the cover.
18
Manually remove the 2 side walls located on
the sides of the sliding contact block.
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Disassembly instruction emaX 2 e2.2
23
Manually remove the 2 springs located at both
sides of the sliding contacts block.
25
By means of the flat screwdriver unhook the
right side wall from the sliding contacts main
assembly as indicated in the picture.
24
Manually remove the auxiliary position
contacts cap located on the left side of the
sliding contacts block.
26
By means of the flat screwdriver unhook the
right side wall from the sliding contacts main
assembly as indicated in the picture.
22
Manually remove the sliding contacts block.
21
By means of the flat screwdriver push up the
3 flat cables assemblies and the connector
cables assembly.
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INSTRUCTION HANDBOOK
29
By means of the cutter start removing the
sliding contacts label located on the right side
wall and manually complete the operation.
31
Lift the sliding contacts base and let the 2 bars
mounted inside exit.
30
Insert 2 flat screwdrivers at the sides of each
block, slightly push them as indicated by the
arrows and complete the removal of the 3 flat
cables assemblies and of the connector cables
assembly manually pulling them.
32
By means of the pliers remove the 4 pins and
the related nuts mounted at both sides of the
sliding contacts base.
27
By means of the flat screwdriver unhook the
right side wall from the sliding contacts main
assembly as indicated in the picture.
28
Manually remove the right side wall.
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Disassembly instruction emaX 2 e2.2
Disassembled parts
(Thermoplastics containing brominated flame
retardants)
(Thermoplastics containing brominated flame
retardants)
containing brominated flame retardants)
(Thermoplastics containing brominated flame
retardants)
containing brominated flame retardants)
containing brominated flame retardants)
brominated flame retardants)
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INSTRUCTION HANDBOOK
6.3 PHASE 3 – TRIP UNIT
Actions to be performed
Tools
No. 8
Pliers
Flat screwdriver
Torx key
Cutter
33
By means of the torx key unscrew the 2 screws
fixing the Ekip measuring blind module located
on the right part of the trip unit to the trip unit
itself.
36
By means of the torx key unscrew the 2 screws
fixing the Ekip measuring blind plug to the
Ekip measuring blind case.
38
Manually remove the printed circuit board.
35
By means of the cutter start removing the label
located on the Ekip measuring blind module
and by means of the pliers complete the
removal operation.
37
Manually remove the Ekip measuring blind
case.
34
By means of the flat screwdriver unhook the
Ekip measuring blind module from the trip unit
and after manually complete the removal.
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Disassembly instruction emaX 2 e2.2
41
Manually unhook the connector located in the
back part of the trip unit.
43
Manually unhook the cables linked to the black
connector.
42
Manually unhook the connector located in the
back part of the trip unit.
44
By means of the flat screwdriver push the black
connector as indicated by the arrow until it’s
totally unhooked and after manually complete
the removal of the trip unit from the circuit
breaker main structure.
40
By means of the cross screwdriver unscrew
the 4 screws fixing the trip unit to the circuit
breaker main structure.
39
By means of the flat screwdriver unhook the
white connector located in the upper part of
the trip unit.
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INSTRUCTION HANDBOOK
47
By means of the cutter start removing the label
mounted over the plug removed at step before
and manually complete the removal operation.
49
Manually push the rating plug case appendix
as indicated by the arrow and by means of the
pliers remove the rating plug printed circuit
board.
48
By means of the flat screwdriver remove the
rating plug from the trip unit.
50
By means of the cutter start removing the label
located on the front of the rating plug case and
by means of the pliers complete the operation.
46
Manually remove the plug.
45
By means of the torx key unscrew the screw
fixing the plug to the trip unit.
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Disassembly instruction emaX 2 e2.2
53
By means of the cutter start removing the
label located on the front of the Ekip signalling
operation.
55
By means of the flat screwdriver unhook the
display from the trip unit main structure.
54
By means of the torx key unscrew the screw
fixing the display to the trip unit main
structure.
56
Manually remove the display from the trip unit
main structure.
52
from the trip unit main structure.
51
By means of the torx key unscrew the 2 screws
unit main structure.
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INSTRUCTION HANDBOOK
59
Manually remove the battery.
61
Manually remove the HMI box from the display.
60
By means of the flat screwdriver unhook the
HMI box from the display.
62
Manually separate the display and the HMI LCD
cover,
58
By means of the flat screwdriver remove the
battery cover on the left side of the display.
57
By means of the cutter start removing the
trip unit front label and by means of the pliers
complete the operation.
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Disassembly instruction emaX 2 e2.2
65
By means of the flat screwdriver unhook the
display printed circuit board from the display
support.
67
Manually separate the display from its printed
circuit board.
66
Manually remove the display support.
68
Manually separate the gasket from the display.
64
Manually remove the battery gasket.
63
By means of the flat screwdriver remove the
“i TEST” pushbutton from the HMI LCD cover.
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INSTRUCTION HANDBOOK
71
By means of the torx key unscrew the 4 screws
fixing the trip unit case to the trip unit back
cover.
73
By means of the flat screwdriver unhook the
trip unit case from the trip unit back cover.
72
By means of the cutter start removing the
blind label located on the side of the trip unit
main structure and by means of the pliers
complete the operation.
74
Manually remove the release case from the
cover.
70
Manually complete the removal operation of
the backplane.
69
By means of the torx key unscrew the 4 screws
fixing the backplane to the trip unit main
structure.
Other manuals for SACE Emax 2 E2.2
7
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